window MAZDA MX-5 1994 Workshop Manual

ABBREVIATIONS 4BDC .... 4BS ...... 4CC ...... 4T ........ 4TDC ..... 4TF ...... 4TS ...... 3AC ...... 3BDC .... 3TDC ..... :ID ....... 2U ....... IOHC .... IRL ...... ITM ...... IC-AT .... iGRA .... EGRV .... ELR ...... EPC ...... ESPS ..... ETS ...... EX ....... FMEM .... HFC ...... HLA ...... H U ....... IC ........ IG ........ IN ........ INT ....... LFC ...... LH ....... LSD ...... M ........ MAF RTN . MT ....... PCTS ..... PCV ...... PIP ....... PRC ...... PIS ....... PMI ...... PWR GND RH ....... RPM ...... RTS ...... SIG RTN . . SLS ...... ... SPOUT S R ....... SST ...... ST ....... SW ....... TDC ...... TNS ...... TRS ...... VPWR .... WSS ..... WTS...... After bottom dead center Antilock brake system Accessory Automatic transmission After top dead center Automatic transmission fluid Ambient temperature sensor Bypass air control Before bottom dead center Before top dead center Cylinder identification display Control unit Double overhead camshaft Daytime running light Diagnostic test mode Electronically controlled automatic transmission EGR air solenoid valve EGR vacuum solenoid valve Emergency locking retractor Electronic pressure control Engine speed sensing power steering Evaporator temperature sensor Exhaust Failure mode effects management High fan control Hydraulic lash adjuster Hydraulic unit Integrated circuit Ignition Intake Intermittent Low fan control Left hand Limited slip differential Motor Mass airflow return Manual transmission Passenger compartment temperature sensor Positive crankcase ventilation Profile ignition pickup Pressure regulator control Power steering Power window Power ground Right hand Revolutions per minute Reduce torque signal Signal return Slip lockup signal Spark output Sensor rotor Special service tool Start Switch Top dead center Tail number side (taillights, license plate lights and side marker lights) Torque reduced signal Vehicle power Wheel speed sensor Water temperature sensor Gartner Banana

PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE The following items may be done at any time prior to delivery to your customer. INSPECT and ADJUST, if necessary, the following items to specification: 0 Glass, exterior bright metal and paint for damage 0 Convertible top and detachable hardtop (if equipped) for damage 0 Wheel lug nuts and locks 89-117 N.m (9-1 2 kgf.m, 66-86 ft4bf) 0 All weatherstrips for damage or detachment Operation of hood release and lock Operation of fuel lid 0 Door operation and alignment Headlight aiming INSTALL the following parts: Wheel caps (if equipped) 0 Outside mirror(s) 0 Mast antenna (if equipped) UNDER HOOD-ENGINE OFF INSPECT and ADJUST, if necessary, the following items to specification : Fuel, coolant, and hydraulic lines, fittings, connections, and components for leaks Engine oil level 0 Power steering fluid level (if equipped) Brake and clutch master cylinder fluid level 0 Windshield washer reservoir fluid level 0 Radiator coolant level and specific gravity 0 Tightness of battery terminals pKiq INSTALL the following parts: CHECK operation of the following items: 0 Seat controls (sliding and reclining) 0 Door locks 0 Seat belts and warning system 0 Air bag system using indicator light (Refer to section T) Ignition switch and steering lock 0 Starter interlock switch (clutch pedal) All lights, including warning, and indicator lights 0 Audible warning system 0 Horn, wipers, and washers Audio system 0 Cigarette lighter Power windows (if equipped) 0 Power outside mirrors (if equipped) 0 Heater, defroster, and air conditioner at all mode selections (if equipped) CHECK the following items: Presence of spare fuses 0 Upholstery and interior finish CHECK and ADJUST, if necessary, the following items: 0 Pedal height and free play of brake and clutch pedals I Pedal height mm {in} I Ft: $iy I Clutch pedal {6.89--7.28) (with carpet) Parking brake 7-9 notchesil96 N (20 kgf, 44 Ibf) 0.63.1 (0.024. 12) Brake pedal RUNNING AT OPERATING TEMPERATURE CHECK the following items: 0 Automatic transmission oil level 171-181 (6.73--7.13) (with carpet) I ON HOIST I 4--7 {0.16-0.28} CHECK the following items: 0 Underside fuel, coolant, and hydraulic lines, fittings, con- nections, and components for leaks 4 Tires for cuts or bruises 0 Steering linkage, suspension, exhaust system, and all underside hardware for looseness or damage Manual transmission oil level Differential oil level I ROAD TEST I CHECK the following items: Brake operation Clutch operation 0 Steering control 0 Operation of meters and gauges Squeaks, rattles and unusual noises 0 Overall engine performance Seat belt emergency locking retractors 0 Cruise control system (if equipped) I AFTER ROAD TEST I CHECK for necessary owner information materials, tools and spare tire in vehicle The following items must be done just before the delivery to your customer. 0 Load test battery and charge if necessary -1 Install fuses for accessories Adjust tire pressure to specification Load test fesuk 0 Remove seat and floor mat protective covers (Refer to Door Label) 0 Vacuum and clean interior of vehicle Clean outside of vehicle Inspect installation of option parts with invoice 45UOAX-002 Gartner Banana

PURGE SOLENOID VALVE 7* AlC RELAY COOLANT FAN RELAY CONDENSER FAN RELAY STARTER STEERING PRESSURE SENSOR AIR CONDITIONING SENSOR ... CHECK VALVE FUEL-FILTER (HIGH-PRESSURE SIDE) / CRANKSHAFT POSITION SENSOR HEATED OXYGEN SENSOR ltT=I THREE-WAY CATALYST - REAR WINDOW DEFROSTER SWITCH COMBINATION SrmCH BLOWER SWlTCH STOPLIGHT SWITCH (MT) CLUTCH SWITCH (MT) - NEUTRALSWrrCH (MT) TEN TERMINAL PARWEUTRAL SWITCH (AT) VEHICLE SPEED SENSOR ENGINE COOLAMTEMPERATURE SENSOR EGR SOLENOID VALVE WEM) EGR SOLENOID VALVE (VACUUM) - w TO PCME Gartner Banana

ENGINE TUNE-UP - TIMING LIGHT - 45UOFX422 GND Irnr Air Cleaner Element Inspection 1. Check the air cleaner element for excessive dirt and for oil and damage. Caution Cleaning the element with compressed air will re- duce the element's ability to filter the air. Don't use compressed air to clean the element. 2. Replace the element if necessary. ADJUSTMENT Preparation 1. Warm up the engine to normal operating temperature. 2. Turn all electric loads OFF. Headlight switch Blower switch Rear window defroster switch 3. Connect the SST to the data link connector. 4. Connect a timing light to the engine. 5. Connect a tachometer to the data link connector terminal IG- as shown. Ignition Timing 1. Perform Preparation. (Refer to above.) 2. Verify that the idle speed is within the specification; if not, adjust it. Idle speed 4 (Neutral): 800-900 (850 + 50) rpm [MT] (P range): 750-850 (800 & 50) rpm [AT] 3. Set switch A to position 1. 4. Set test switch to SELF TEST. 5. If the SST is not used, connect a jumper wire between the TEN terminal and the GND terminal of the data link connector. 6. Verify that the idle speed is within the specification. ldle speed (Ground the terminal TEN): 650-975 rpm 7. Verify that the timing mark (white) on the crankshaft pulley and the mark on the timing belt cover are aligned. lgnition timing: BTDC 9"-11" (10" & lo) Gartner Banana

ON-BOARD DIAGNOSIS SYSTEM SWITCH MONITOR FUNCTION Inspection Procedure POWERTRAIN CONTROL MODULE (ENGINE) NEUTRAL SWITCH CLUTCH SWITCH 1 STOPLIGHT SWITCH HEADLIGHT SWITCH REAR WINDOW DEFROSTER SWITCH PARKINEUTRAL SWITCH IDLE SWITCH (IN THROTTLE POSITION SENSOR) BLOWER SWITCH AIR CONDITIONING SENSOR I ' SYSTEM MONITOR LAMP (SELF-DIAGNOSIS 1 Clutch switch (MT) 1 Pedal released I Pedal depressed I In gear I Switch Self-Diagnosis Checker (Monitor lamp) I Liaht ON Liaht OFF . . I I I - I Idle switch (in throttle position sensor) I Pedal depressed I Pedal released 1 Remark ParWneutral switch (AT) I L, S, D and R range I N and P range I I I Stoplight switch (MT) Pedal depressed I Pedal released - I Neutral I Clutch pedal released Neutral switch (MT) - In gear I I Blower switch Headlight switch OFF Blower motor position: "medium" "high" or "super hiah" position I I ON 1. Connect the SST to the data link connector as shown. 2. Turn the ignition switch ON. Check if the monitor lamp il- luminates when each switch is made to function as de- scribed below. If any switch remains activated, the monitor lamp will be illuminated. 3. Connect the SST to the data link connector as shown. 4. Turn the ignition switch to ON (engine off). Check if the monitor lamp illuminates when each switch is adjusted as described above. 45UOFX-173 OFF 1 Air conditioning sensor Rear window defroster switch - ON ON OFF OFF Fan speed control: Low position - Gartner Banana

F ON-BOARD DIAGNOSIS SYSTEM Procedure - Set conditions to deactivate each switch a All accessories OFF a Transmission in neutral a All pedals released Verify that monitor lamp does not illuminate Neutral and Clutch switches (MT) Parklneutral switch (AT) Depress clutch pedal Verify that monitor lamp does not illuminate Return transmission to neutral NO PC: a Neutral or clutch switch malfunction (Refer to F-146) a Open circuit in related wire harness a Powertrain control module (engine) terminal 1V malfunction (Refer to page F-146) - Shift transmission into gear Verify that monitor lamp illuminates with clutch pedal is re- leased PC: a Clutch switch malfunction (Refer to page F-157) 35UOFX-046 I ParWneutral switch OK Shift into P or N range Check each switch and related wire harness a Clutch and Neutral switch :Refer to page F-I57 a Idle switch (in throttle position sensor) :Refer to page F-154 a Stoplight switch :Refer to Section T Headlight switch :Refer to Section T 1 Check each switch as described I I NO - ldle switch (in throttle position sensor) a Blower switch :Refer to Section T a Air conditioning sensor :Refer to Section U a Rear window defroster switch :Refer to Section T a ParWneutral switch :Refer to Section K YES PC: a ParWneutral switch malfunction (Refer to Section K) a Open or short circuit in related wire harness a PCME terminal 1 V voltage incorrect (Refer to page F-I 46) PCME malfunction - Shift transmission into L, S, D, or P range Check that monitor lamp illuminates 35UOFX-06 NO + YES I 1 I ldle switch OK I L I PC: Throttle position sensor malfunction (Refer to page F-144) a Short circuit in wire harness from throttle position sensor to PCME a PCME terminal 1 N voltage incorrect (Refer to page F-145) a PCME malfunction - Depress accelerator pedal and check that monitor lamp illu- minates f NO --c YES PC: a Throttle position sensor malfunction (Refer to page F-144) Open circuit in wire harness from throttle position sensor to PCME PCME terminal 2M voltage incorrect (Refer to page F-146) Release acceleration pedal and check that monitor lamp does not illuminate 2 YES I I Gartner Banana

ON-BOARD DIAGNOSIS SYSTEM Stoplight switch OK Release brake pedal Stoplight switch (MT) Headlight switch PC: Stoplight switch malfunction (Refer to Section T) 0 Open circuit in wire harness from stoplight switch to powertrain control module (engine) Powertrain control module (engine) terminal 10 malfunction (Refer to page F-145) Headlight switch OK Turn OFF headlight switch I I NO ---c L, Blower switch YES Depress brake pedal and verify that monitor lamp illuminates PC: Headlight switch malfunction (Refer to section T) Open circuit in wire harness from headlight switch to powertrain control module (engine) Powertrain control module (engine) terminal 1 U malfunction (Refer to page F-146) Turn ON headlight switch Verify that monitor lamp illuminates Verify that monitor lamp illuminates NO - I YES YES Blower switch OK Turn OFF blower switch Air conditioning sensor PC: Blower switch malfunction (Refer to section T) 0 Open circuit in wire harness from blower switch to powertrain control module (engine) 0 Powertrain control module (engine) terminal IS malfunction (Refer to page F-146) 1 I YES I ' Set fan speed control to low position Turn air conditioning sensor ON, and verify that monitor lamp illuminates PC: Air conditioning sensor malfunction (Refer to Section U) Blower switch malfunction Open circuit in wire harness from air conditioning sensor to blower switch Powertrain control module (engine) terminal 1Q malfunction (Refer to page F-146) NO' 4 Air conditioning sensor OK Turn air conditioning sensor and blower switch OFF Rear window defroster switch Turn rear window defroster switch ON Is monitor lamp illuminated? NO PC: Rear window defroster switch malfunction (Refer to Section T) Open circuit in wire harness (Rear window defroster switch - PCME) PCME terminal 2L voltage incorrect (Refer to page F-146) PCME malfunction YES Turn rear window defroster switch OFF u Rear window defroster switch OK Gartner Banana

F CONTROL SYSTEM B+: Battery positive voltage Connection to 1 Test condition 1 Voltage I Remark I -- EGR solenoid valvi Idle B+ Blower switch -- EGR solenoid valve (vacuum) :vent) Initial acceleration* Blower switch at mid, high or su- per high position Blower switch OFF or low Headlight switch Neutral or clutch switch (MT) B+ Idle ParWneutral switch (AT) Ground (Injector) Ground (Output) Ground (PCME) Approx. OV - Approx. 12V B+ Headlights ON (Tail, parking, low beamfhigh beam) Headlights OFF Neutral position or clutch pedal de- pressed Other conditions Ground (Input) Crankshaft position (SGT-signal) Ignition switch ON N or fJ range Other conditions Constant Constant Constant -. Mass airflow sensor .. . . EGR function sensor I while running Approx. 0-5v Initial acceleration* Approx, 2V OV ov B+ Constant Ignition switch ON Idle Crankshaft position sensor (SGC-signal) Data link connector (TEN terminal) Igniter I I I Vre f I lanition switch ON 1 4.5-5.9.' 1 - B+ - OV B+ OV OV OV Ignition switch ON Idle - - - OV OV or 5V ADD~OX. 2V - - Ignition switch ON Idle System Selector test switch at "02 MONITOR" System Selector test switch at "SELF-TEST" Ignition switch ON Idle lanition switch ON I . . I I 1 Ignition switch ON I Below 1 .OV I I - - . . Below 1 .OV Below 1 .OV ear window defrost- er relay Throttle position sensor Heated oxygen sensor - OV or 5V Approx. 1.5V B+ ov Below 0.5V Approx. 1 V Approx. 1 .OV - - - " Rear window defroster switch OFF Rear window defroster switch ON Accelerator pedal released Accelerator ~edal fullv de~ressed Mass airflow sensor B+ Below 1 .OV 0.1-1 .o 3.14.5 Intake air temperature sensor Engine coolant tem- perature sensor lgnition switch ON lgnition switch ON Ignition switch ON Idle ireen and red lamps flash At 200C {680Fj Engine coolant temperature 20°C {680F) After warm-up Below 1 .OV 1 .O-2.0 - Approx. 2.5V Approx. 2.5V Approx. 0.4V Built in mass airflow lgnition switch ON Gartner Banana

F CONTROL SYSTEM B+: Battery positive voltage Abnormal voltage Possible cause Terminal 1 v Connection to Neutral switch malfunction (Refer to page F-157) Clutch switch malfunction (Refer to page F-156) Short circuit in wiring from PCME terminal 1 V to neutral or clutch switch Neutral switch malfunction (Refer to page F-157) 0 Clutch switch malfunction (Refer to page F-156) 0 Open circuit in wiring from PCME terminal 1 V to neutral or clutch switch Poor connection at PCME connector 0 ParWneutral switch malfunction (Refer to section K) 0 Short circuit in wiring from parWneutral switch to PCME terminal 1V 0 ParWneutral switch malfunction (Refer to section K) 0 Open circuit in wiring from parWneutral switch to PCME terminal 1 V Always OV Neutral switchlClutch switch (MT) Always B+ Always OV ParWneutral switch (AT) Always B+ Poor contact at ground terminal 0 Open circuit in wiring from PCME to ground Sround More than OV Crankshaft position sensor (SGT-signal) Always OV or approx. 5V Always below 2V or 4V Refer to Code No.03 troubleshooting (Refer to page F-84) Refer to code No.08 Troubleshooting (Refer to page F-86) 0 Short circuit in wiring from PCME terminal 2H to data link connector terminal TEN Mass airflow sensor Always OV Data link connector (Terminal TEN) 0 Open circuit in wiring from PCME terminal 2H data link connector terminal TEN 0 Open circuit in wiring from data link connector terminal GND to around Always B+ Igniter EGR function sensor Always OV Always approx. OV or approx. 5v Refer to Code No.01 troubleshooting (Refer to paae F-83) 0 Refer to Code No.16 Troubleshooting (Refer to page F-89) 0 Short circuit in wiring from PCME terminal 2K tothrottle position sensor, PCME, or mass airflow sensor Poor connection at PCME connector PCME malfunction Vre f Always OV lllumination light ON when rear window defroster switch ON Open or short circuit in wiring from rear window de- froster switch to PCME terminal 2L Always below 1 .ov Rear window defroster switch Open circuit in wiring from ignition switch to rear win- dow defroster switch Rear window defroster switch malfunction (Refer to section T) lllumination light never ON Open circuit in wiring from PCME terminal 2M to throttle position sensor 0 Open circuit in wiring from PCME terminal 2K to throttle position sensor 0 Open circuit in wiring from PCME terminal 20 to throttle position sensor Always constant Throttle position sensor Alwavs above 1V 0 Throttle position sensor misadjustment Refer to Code No.15 troubleshooting (Refer to page F-88) OV after warm-up Heated oxygen sensor Always approx, 1V after warm-up 0 Refer to Code No.17 troubleshooting (Refer to page F-90) Refer to Code No.08 troubleshooting (Refer to page F-86) Mass airflow sensor Always OV or approx. 5V Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . BODY INDEX ............................. S- 2 HOOD ............................. S- 5 COMPONENTS ................... S- 5 DOOR ............................. S- 7 COMPONENTS ................... S- 7 WINDOW REGULATOR. GLASS. AND GUIDE ....................... S- 9 COMPONENTS ................... S- 9 ......... DOOR LOCK AND OPENER S-15 ................... COMPONENTS S-15 TRUNK LID ........................ S-16 COMPONENTS ................... S-16 .... TRUNK LID LOCK AND OPENER S-18 COMPONENTS ................... S-18 ......... POWER WINDOW SYSTEM S-19 .............. STRUCTURAL VIEW S-19 TROUBLESHOOTING ............. S-20 ........ b POWER WINDOW SWITCH S-22 ... POWER WINDOW REGULATOR S-22 ......... FUEL-FILLER LID OPENER S-23 COMPONENTS ................... S-23 FRONT BUMPER ................... S-24 COMPONENTS ................... S-24 REAR BUMPER .................... S-25 COMPONENTS ................... S-25 ........... MOLDING AND GARNISH S-27 COMPONENTS ................... S-27 OUTSIDE MIRROR ................. S-30 STRUCTURAL VIEW .............. S-30 ............. TROUBLESHOOTING S-31 POWER OUTSIDE MIRROR ....... S-33 POWER OUTSIDE MIRROR SWITCH ........................ S-33 COMPONENTS ................... S-34 WINDSHIELD WIPER AND WASHER . S-35 TROUBLESHOOTING ............. S-35 WIPER MOTOR .................. S-38 ................ WASHER MOTOR S-38 FRONT WIPER AND WASHER ........................ SWITCH S-38 ................... COMPONENTS S39 WINDSHIELD ...................... S-44 PREPARATION ................... S-44 ................... COMPONENTS S-44 REAR WINDOW GLASS ......... (DETACHABLE HARDTOP) S-48 PREPARATION ................... S48 ................... COMPONENTS S48 REAR WINDOW .............. (CONVERTIBLE TOP) S-52 ................... COMPONENTS S-52 ....... DASHBOARD AND CONSOLE S-56 ................... COMPONENTS S56 TRIM .............................. S-59 COMPONENTS ................... S-59 ................. FLOOR COVERING S-62 ................... COMPONENTS -21 SEAT BELT ........................ S-63 COMPONENTS ................... S-63 ...................... SEAT BELT S-64 ................ BUCKLE SWITCH S-64 SEAT .............................. S-65 ................... COMPONENTS S-65 ................ CONVERTIBLE TOP S-67 PREPARATION ................... S-67 ................... COMPONENTS S-67 ........... DETACHABLE HARDTOP S-81 COMPONENTS ................... S-81 BRACE BAR ....................... S-84 ................... COMPONENTS S-84 ......... UNDERBODY DIMENSIONS S-85 PROJECTED DIMENSIONS ........ S-85 ..... STRAIGHT-LINE DIMENSIONS S-87 45uoSx-001 Gartner Banana